With the steel work done on the VW bug hood, I can start building up the edges with epoxy filler. I used foil and cardboard to make sure that the hood could still separate from the body. Once the filler set up I ground it down to match the curve of the body and fender. I am also working on the front bumper and light pods.
Now the VW bug fenders widened, I can focus on the hood. This is the original hood from the car and I am trying to keep it. It has been tricky to get new metal to bond to old metal, but I kept working on it till I got it. It’s now ready for refit and filler.
After a lot more work, I have finally completed the widening of the VW bug steel fenders. I now must get the hood (big job) and the rear deck lid to fit and get them ready for body filler. The sheet metal is close to be finished.
I was having trouble with my fuel pump it couldn’t keep up with the turbo. I am replacing the pump with an in-tank Aeromotive 90 PSI unit. Summit Racing returned one pump for the other. I have created a stainless steel fuel pump hanger to get the pump to the bottom of the tank. It all seems to work fine, so back to the fenders.
With both of the widened VW bug’s front and rear fenders as well as the running board positioned, I can now concentrate on paneling in the openings. I am using 22 gauge steel plates that I am cutting to fit in each void. First I develop the paper template and then cut and fit each plate. I am using a spot welder which can only fit inside the fender on every other plate. Once I have as many plates on that I can get with the fender mounted, I will remove the fender and finish up all the plates and welding from the other side. Using a hammer I can refine the shape before applying the filler. I painted the fender with some guide coat spray paint to get an idea how It’s going to look.
I have a lot of work to do to get the running boards to mate up with the VW bug fenders. The replacement running boards are cheaply made and require quite a bit of steel reinforcement to make everything solid. But I basically have the passenger side of the VW bug fenders widened as well as the running board. With the passenger side mocked up I can now repeat the process on the driver’s side. Once all the fenders are positioned I can panel in all the openings.
With both the front and rear aprons on, I can start mock-up on one complete side of the VW bug. I searched high and wide to find some hints on widening fenders, found none, this is how I am doing it. I am installing small support tabs to try and shape the fender. I will finish widening the fenders and running-board with small steel plates.
Now with the rear apron in place I can go ahead and start positioning the VW bug widened fenders. Since the front fenders will also be widened I must position the front sheet metal all at once. Once everything was positioned I drilled small holes through the front apron flanges to reposition for welding. I am ready to widen the front fenders.
To finish up the exhaust I must determine where the two tail pipes are going to attach to the 3 inch main tube. To do this I need to finalize the rear apron and to do that I need to fit all of the rear sheet-metal. I fit the rear fenders, deck lid and apron and then welded on the apron and marked out the holes for the exhaust tips. Each tip is stainless like the main tube.
Once all the interior panels were created I covered everything with the sound deadening and heat blocking materials. The underside of the engine compartment lids have a fiberglass/foil material applied that is good to 1200 degrees F. Everything is now sealed off from the passenger compartment.